Systems and methods for manufacturing orthodontic devices

ABSTRACT

In some embodiments, apparatuses and methods are provided herein useful to orthodontic kits. In some embodiments, an orthodontic kit comprises a carrier, wherein the carrier is configured to house a plurality of orthodontic appliances, the plurality of orthodontic appliances, and a plurality of support structures, wherein the plurality of support structures includes groups of support structures, wherein each group of support structures connects one of the plurality of orthodontic appliances to the carrier, wherein the orthodontic kit is defined by a computer data file, wherein the computer data file includes data necessary to additively manufacture the orthodontic kit including the carrier, the plurality of orthodontic appliances, and the plurality of support structures.

TECHNICAL FIELD

This invention relates generally to orthodontics and, more specifically,the manufacture of orthodontic appliances.

BACKGROUND

Orthodontic clinicians seek to correct malocclusions by use of manydifferent devices, such as braces, retainers, pallet expanders,positioners, etc. Braces, one of the most commonly used devices, includea number of orthodontic appliances such as brackets, archwires, andligatures. The brackets are affixed to a patient's teeth and thearchwire passes through slots in the brackets designed to receive thearchwire. The ligatures secure the archwire within the slots. Because notwo patients have identical malocclusions or facial geometries, theprescription for each patient's braces must be selected by theclinician. A prescription for braces typically includes specificallyselected brackets, archwires, and ligatures. For example, a largepractice may have an orthodontic bracket inventory costing over $50,000.Not only does this bracket inventory represent a large overhead forclinicians, it can prevent smaller practices from being able to dobusiness. Consequently, a need exists for systems, methods, andapparatuses that minimize the need for clinicians to stock a largenumber of orthodontic appliances to treat patients.

BRIEF DESCRIPTION OF THE DRAWINGS

Disclosed herein are embodiments of systems, apparatuses, and methodspertaining to orthodontic kits. This description includes drawings,wherein:

FIG. 1 is a perspective view of an orthodontic kit 100 including acarrier 102, orthodontic appliances 104, and support structures 106,according to some embodiments;

FIG. 2A is a side elevation view of an orthodontic kit 200 including acarrier 208, orthodontic appliances 202, and support structures 206,according to some embodiments;

FIG. 2B is a top view of an orthodontic kit 200 including a carrier 208,orthodontic appliances 202, and support structures 206, according tosome embodiments;

FIG. 3 is a perspective view of an orthodontic appliance 302 connectedto a base 304 via support structures 306, according to some embodiments;

FIG. 4A is a perspective vies of an orthodontic appliance 402, accordingto some embodiments;

FIG. 4B is a perspective view of a base 404, according to someembodiments;

FIG. 5A is a perspective view of an orthodontic appliance 502 and a base504, according to some embodiments;

FIG. 5B is a perspective view of an orthodontic appliance 510 connectedto a base 512 via support structures 514, according to some embodiments;

FIG. 6 is a perspective view of an orthodontic kit 600 oriented in abuild plane 602, according to some embodiments;

FIG. 7 is a block diagram of a system 700 for additively manufacturingorthodontic kits, according to some embodiments; and

FIG. 8 is a flow chart including example operations for additivelymanufacturing orthodontic kits, according to some embodiments.

Elements in the figures are illustrated for simplicity and clarity andhave not necessarily been drawn to scale. For example, the dimensionsand/or relative positioning of some of the elements in the figures maybe exaggerated relative to other elements to help to improveunderstanding of various embodiments of the present invention. Also,common but well-understood elements that are useful or necessary in acommercially feasible embodiment are often not depicted in order tofacilitate a less obstructed view of these various embodiments of thepresent invention. Certain actions and/or steps may be described ordepicted in a particular order of occurrence while those skilled in theart will understand that such specificity with respect to sequence isnot actually required. The terms and expressions used herein have theordinary technical meaning as is accorded to such terms and expressionsby persons skilled in the technical field as set forth above exceptwhere different specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION

Generally speaking, pursuant to various embodiments, systems,apparatuses and methods are provided herein useful to orthodontic kits.In some embodiments, an orthodontic kit comprises a carrier, wherein thecarrier is configured to house a plurality of orthodontic appliances,the plurality of orthodontic appliances, and a plurality of supportstructures, wherein the plurality of support structures includes groupsof support structures, wherein each group of support structures connectsone of the plurality of orthodontic appliances to the carrier, whereinthe orthodontic kit is defined by a computer data file, wherein thecomputer data file includes data necessary to additively manufacture theorthodontic kit including the carrier, the plurality of orthodonticappliances, and the plurality of support structures.

As previously discussed, because no two patients have identical dentalor facial structures, many orthodontic appliances are specially designedor selected for each patient. While some orthodontic appliances arecustom-molded for patients, such as clear aligners, other orthodonticappliances, such as brackets, come in a variety of prescriptions and areselected by the clinician based on the patient's dental and/or facialgeometry. With regard to brackets, clinicians select from among thecommercially available prescriptions to choose brackets for each of apatient's teeth. While the total number of commercially availablebrackets is quite large, a smaller subset of all brackets is used totreat the majority of patients. For example, though the total number ofcommercially available brackets numbers in the thousands, the majorityof patients are treated using only about 20% of those brackets.Accordingly, orthodontic practices may try to keep all of these “common”brackets on hand so that patients can be analyzed and treated promptly(e.g., during the same day, week, etc.). While maintaining such a largeinventory may be feasible for large practices, maintaining, or building,such an inventory may be cost prohibitive for small and/or newpractices. Additionally, even if a practice is capable of maintainingsuch an inventory, it is likely not cost effective.

Described herein are systems, methods, and apparatuses that seek tominimize or overcome this problem by allowing clinicians to quickly andaffordably manufacture orthodontic kits including orthodontic appliances(e.g., brackets, retainers, pallet expanders, etc.). In one embodiment,clinicians are provided with data files (e.g., computer-aided designfiles (CAD), such as .stl files). The clinicians then manufactureorthodontic kits based on the data files with additive manufacturingtechniques. As one example, a clinician can select an orthodonticappliance that he or she would like to use to treat a patient. Thesystem provides a data file associated with an orthodontic kit to theclinician. The orthodontic kit includes the orthodontic appliance. Theclinician then, using a manufacturing device, manufactures theorthodontic kit in his or her office. This manufacturing-on-demandeliminates, or at least reduces, the number of orthodontic appliancesthat a clinician must have on hand to promptly treat patients. Not onlydoes this allow clinicians to promptly treat patients, but it alsoreduces costs for the clinician and thus the patient. The discussion ofFIG. 1 provides an overview of such an orthodontic kit.

FIG. 1 is a perspective view of an orthodontic kit 100 including acarrier 102, orthodontic appliances 104, and support structures 106,according to some embodiments. The carrier 102 is configured to housethe orthodontic appliances 104. The support structures 106 connect theorthodontic appliances 104 to the carrier 102. The support structures106 comprise groups of support structures 106. Each group of supportstructures 106 connects one of the orthodontic appliances 104 to thecarrier 102.

In one embodiment, the orthodontic kit 100 is additively manufactured,such as by way of the techniques described in U.S. patent applicationSer. No. 16/875,618 titled SYSTEMS AND METHODS FOR MANUFACTURE OFORTHODONTIC APPLIANCES filed on May 15, 2020 and incorporated byreference herein in its entirety. For example, the orthodontic kit 100can be additively manufactured by a 3D printing process. In suchembodiments, the orthodontic kit 100 is additively manufactured as asingle unit (e.g., structure). Accordingly, the carrier 102, orthodonticappliances 104, and support structures 106 are additively manufacturedas a single unit. Further, the orthodontic kit 100 can be defined by acomputer data file (e.g., a CAD file, such as an .stl file). Thecomputer data file includes all of the data necessary to additivelymanufacture the orthodontic kit 100. That is, the computer data fileincludes all of the data necessary to additively manufacture the carrier102, the orthodontic appliances 104, and the support structures 106. Insome embodiments, the orthodontic kit 100 can be additively manufacturedwithout additively manufacturing anything in addition to the orthodontickit 100. For example, the orthodontic kit 100 can be additivelymanufactured without the need for additional supports, bases, etc.

The support structures 106 provide a structure upon which theorthodontic appliances 104 can be additively manufactured. In someembodiments, the support structures 106 are specific to the orthodonticappliances 104. For example, different types of orthodontic appliances104 may require different types of support structures 106 for theorthodontic appliances 104 to be additively manufactured correctly. Insuch embodiments, the groups of support structures 106 may havedifferent types and the different types of groups of support structures106 may be specific to different types of orthodontic appliances 104.The type of the group of support structures 106 can be based on thedimensions of the orthodontic appliances 104, features of theorthodontic appliances 104 (e.g., presence or lack of hooks), parametersof the orthodontic appliances 104 (e.g., a tip angle of a bracket), etc.For example, a bracket with a hook can be oriented parallel to thecarrier 102 and include five support structures 106 (as depicted betweenFIGS. 4A and 4B), a bracket without any hooks can be oriented parallelto the carrier 102 and include four support structures 106 (as depictedin FIG. 5A), and a molar tube can be oriented normal to the carrier 102and include three support structures 106 (as depicted in FIG. 5B).Further, the shape, placement, geometry, etc. of the support structures106 can be tailored to the device associated with the support structures106. Because the data necessary to additively manufacture theorthodontic kit 100 includes the data necessary to additivelymanufacture the support structures 106, the support structures can bedesigned as desired based on the orthodontic appliances 104. Forexample, the support structures 106 can be designed such than nointernal supports are necessary for the orthodontic appliances 104.Additionally, as described in more detail with respect to FIGS. 3 and 4,the support structures 106 can be designed such that the orthodonticappliances 104 are easily removable from the support structures 106.

While the discussion of FIG. 1 provides an overview of an orthodontickit that can be additively manufactured, the discussion of FIG. 2provides additional information regarding such an orthodontic kit.

FIG. 2A is a side elevation view, and FIG. 2B is a top view, of anorthodontic kit 200 including a carrier 208, orthodontic appliances 202,and support structures 206, according to some embodiments. Theorthodontic kit 200 includes a carrier 208, orthodontic appliances 202,and support structures 206. In one embodiment, the orthodontic kit 200is additively manufactured a single unit. That is, the carrier 208,support structures 206, and orthodontic appliances 202 are a singlestructure. In such embodiments, the orthodontic kit 200 can be definedby a computer data file. Though the orthodontic kit 200 is referred toas being defined by a computer data file, the computer data file can bea composite of multiple computer data files. For example, the carrier208 may be common to multiple orthodontic kits 200. In this example, acomputer data file that defines the carrier 208 may be references in thecomputer data file that defines the orthodontic kit 200. Additionally,in some embodiments, the orthodontic appliances 202 may be defined bycomputer data files specific to each orthodontic appliance 202. Forexample, a bracket, pallet expander, etc. having a specific prescriptionor parameters may be defined by a computer data file. The computer datafile that defines the orthodontic appliances 202 may also define thesupport structures 206 for the associated one of the orthodonticappliances 202. In embodiments in which the computer data file thatdefines the orthodontic kit 200 includes multiple data files (e.g., acomputer data file defining the carrier 208, computer data filesdefining the orthodontic appliances 202, and/or computer data filesdefining the support structures 206), the computer data file thatdefines the orthodontic kits 200 may be a composite of multiple computerdata files.

In some embodiments, the carrier 208 is structured geometrically toprovide protection to the orthodontic appliances 202 housed within thecarrier 208. For example, the carrier 208 can include protrusions,indentations, etc. that decrease the likelihood of the orthodonticappliances 202 being damaged if the orthodontic kit 200 is, for example,dropped, jostled, struck by another object, etc. As but one example andas depicted in FIGS. 2A and 2B, the carrier 208 includes a raised rail204. As seen in FIG. 2A, the raised rail 204 extends above theorthodontic appliances 202. In one embodiment, the raised rail 204extends above the orthodontic appliances 202 in such a manner that ifthe orthodontic kit 200 is placed upside down (e.g., with theorthodontic appliances 202 facing a surface such as the floor or atable), the raised rail 204 and edge(s) of the carrier 208 contact thesurface as opposed to the orthodontic appliances contacting the surface.Though the example depicted in FIGS. 2A and 2B includes only one raisedrail 204, embodiments are not so limited. For example, the carrier 208can include multiple raised portions. Similarly, the carrier 208 can bedesigned with wells 210 that are below a surface of a portion of thecarrier 208 such that the orthodontic appliances 202 are less likely tobe damaged should the orthodontic kit 200 be mishandled.

Further, in some embodiments, the orthodontic kit 200 can includemarkings 212, such as those described in more detail with respect toU.S. Nonprovisional application Ser. No. 17/011,071 titled SYSTEMS ANDMETHODS FOR MARKING ORTHODONTIC DEVICES filed on Sep. 3, 2020, which ishereby incorporated by reference in its entirety. The markings 212 canbe located on the carrier 208 and/or orthodontic appliances 202. In oneembodiment, markings 212 are integral to the orthodontic kit 200 (i.e.,are manufactured as part of the orthodontic kit 200). In suchembodiments, the data necessary to additively manufacture theorthodontic kit can include data to additively manufacture the markings212. The markings 212 can convey any desired information, such as aprescription associated with the orthodontic kit 200 and/or theorthodontic appliances, a database record in a database, positions ofthe orthodontic appliances, etc.

While the discussion of FIGS. 1 and 2 describes an orthodontic kit, thediscussion of FIG. 3-5 provides additional detail regarding connectionof orthodontic appliances to a carrier via support structures. Theorthodontic appliances are secured to the carrier via the supportstructures. The shape, location, geometry, number, features, etc. of thesupport structures can vary based on the type of orthodontic appliance.There are several considerations for the support structures. First, insome embodiments, it is desirable for the support structures to provideadequate surface area such that the orthodontic appliance can beadditively manufactured on top of the support structures. For example,if the support structures are too small (e.g., the surface area of theportion of the support structure upon which the orthodontic appliance ismanufactured is too small), too few in number, not spaced appropriately,etc., the orthodontic appliance may not be dimensionally accurate (e.g.,the material used to additively manufacture the orthodontic appliancemay sag or otherwise be unable to maintain its integrity). Second, insome embodiments, it is desirable for the orthodontic appliance to becleanly severable from the support structures such that no, or acontrolled portion of, residue remains on the orthodontic applianceafter the orthodontic appliance is severed from the support structures.Third, in some embodiments, it is desirable to place the supportstructures relative to the orthodontic appliance such that no internalsupports are necessary for the additive manufacture of the orthodonticappliance. FIGS. 3-5 depict various orthodontic appliances and exampleshapes, locations, geometries, numbers, and features of supportstructures. Additionally, FIGS. 3-5 depict varying orientations of theorthodontic appliances with respect to the carrier.

FIG. 3 is a perspective view of an orthodontic appliance 302 connectedto a base 304 via support structures 306, according to some embodiments.As depicted in FIG. 3, the orthodontic appliance 302 is a bracket. Aspreviously discussed, the orthodontic appliance 302 includes a hook and,in this example, includes five associated support structures 306. Thoughthe example depicted in FIG. 3 includes a bracket, embodiments are notso limited. That is, the orthodontic appliance 302 can be of anysuitable type. In some embodiments, the orthodontic appliance 302, thesupport structures 306, and the base 304 are manufactured (e.g.,printed) as a single unit (e.g., as part of an orthodontic kit). Thoughthe base 304 is depicted in FIG. 3 as a separate structure, embodimentsare not so limited. For example, the base 304 can simply be a portion ofa larger structure, such as a carrier, as descried with respect to FIGS.1-2.

The support structures 306 connect the orthodontic appliance 302 to thebase 304 at a joint 308. In one embodiment, the joint 308 has a doubletaper configuration. In the double taper configuration, both ends of thejoint 308 taper to a section that is, for example, thinner than the restof the support structure 306 or otherwise includes less material thanthe rest of the support structure 306. The thinning of the supportstructure 306 at the joint 308 allows the orthodontic appliance 302 tobe detached from the base 304 by a user via physical input. The geometryof the joint 308 focuses stress from physical manipulation of theorthodontic appliance 302 and/or base 304 at a desired location withinthe joint 308. Accordingly, such joint 308 geometry allows for a cleanfracture of the material at, or near, the joint 308. In someembodiments, the orthodontic appliance 302 can be separated from thesupport structure 306 without leaving any excess material (e.g.,residue) on the orthodontic appliance 302.

Additionally, in some embodiments, the locations, numbers, positions,etc. of the support structures 306 can be user-defined. For example, theuser can select precise locations of the support structures 306 based onthe geometry and/or features of the orthodontic appliance 302. In suchembodiments, the support structures 306 can be included in the data filefor the orthodontic appliance bracket 302. This provides the user withability to locate the support structures 306 as desired to facilitateclean and/or easier separation of the orthodontic appliance 302 from thebase 304.

FIG. 4A is a perspective view of an orthodontic appliance 402 and FIG.4B is a perspective view of a base 404, according to some embodiments.As depicted between FIGS. 4A and 4B, the orthodontic appliance 402 isseverable from the support structures 4006, and thus the base 404 (e.g.,the carrier). In the example provided in FIGS. 4A and 4B, the placementof the support structures 406 and the joints is such that nubs 408remain on the orthodontic appliance 402 when the orthodontic appliance402 is removed from the base 404.

FIG. 5A is a perspective view of an orthodontic appliance 502 and a base504. As previously discussed, the orthodontic appliance 502 is a bracketwithout hooks and, in this example, includes four support structures506. FIG. 5A depicts the orthodontic appliance as having been removedfrom the base 504. That is, in FIG. 5A, the orthodontic appliance 502 isno longer affixed to the base 504 via the support structures 506.

The support structures 506 depicted in FIG. 5A include a steppedconfiguration 508. The stepped configuration 508, in some embodiments,allows the orthodontic appliances 502 to be cleanly severed from thesupport structures 506. For example, the orthodontic appliance 502 canbe cleanly severed from the support structures 506 such that no, little,or a controlled amount of residue remains on the orthodontic appliances502 once it has been removed from the support structures 506. In oneembodiment, the stepped configuration 508 is defined in a layer-by-layermanner in a data file with which the orthodontic appliance 502 isassociated. In this manner, the degree to which each layer of thestepped-configuration 508, the height of each layer of thestepped-configuration 508, the length of the stepped configuration 508,end dimension of the stepped configuration 508, etc. can be user-definedas desired based on the specific orthodontic appliance 502 with whichthe support structures 506 are associated.

FIG. 5 5B depicts an orthodontic appliance 510 affixed to a base 512 viasupport structures 514. As previously discussed, the orthodonticappliance 510 is a molar tube and, in this example, includes threesupport structures 514. Additionally, in this example, the orthodonticappliance 510 is oriented normal to the base 512 and thus the carrier(not pictured). Like the support structures in FIG. 5A, the supportstructures 514 depicted in FIG. 5B include a stepped configuration 516.

While the discussion of FIGS. 1-5 provides additional informationregarding an orthodontic kit and orthodontic appliances included withthe orthodontic kit, the discussion of FIGS. 6-8 provides additionaldetail regarding the manufacture of such an orthodontic kit.

FIG. 5 is a perspective view of an orthodontic kit 600 oriented in abuild plane 602, according to some embodiments. As previously discussed,in some embodiments, the orthodontic kit 600 can be additivelymanufactured. Typically, when a product is additively manufactured, auser has control of the orientation and/or placement of the product in abuild plane of the manufacturing device. As previously discussed, insome embodiments, the orthodontic kit 600 can be manufactured withoutmanufacturing anything in addition to the orthodontic kit 600. In someembodiments, this can be accomplished by including an orientation of thecarrier 604 of the orthodontic kit 600 in the computer data file. Forexample, as depicted in FIG. 5, the orientation of the carrier 604 isnormal to the build plane 602. Such an orientation allows theorthodontic kits 600 to be additively manufactured without the need forthe generation and/or manufacture of any additional supports external tothe orthodontic kit 600. In some embodiments, the computer data file canbe protected such that a user is not able to manipulate the orthodontickit 600 and/or the orientation of the orthodontic kit 600 in the buildplane 602 to insure consistency and quality of the orthodontic kit 600.

While the discussion of FIG. 6 provides additional information regardingan orientation of an orthodontic kit during manufacture of theorthodontic kit, the discussion of FIG. 7 provides additional detailregarding the manufacture of an orthodontic kit.

FIG. 7 is a block diagram of a system 700 for additively manufacturingorthodontic kits, according to some embodiments. The system 700 includesa control circuit 702, a database 704, a user device 710, and amanufacturing device 718. One or more of the control circuit 702, thedatabase 704, the user device 710, and the manufacturing device 718 arecommunicatively coupled via a network 708. The network 708 can include alocal area network (LAN) and/or wide area network (WAN), such as theInternet. Accordingly, the network 708 can include wired and/or wirelesslinks.

The user device 710 can be any suitable type of computing device (e.g.,a desktop or laptop computer, smartphone, tablet, etc.). The user device710 includes a display device 712. The display device 712 is configuredto present a catalogue to a user. The catalogue includes orthodonticdevices that the user can obtain via the system 700. For example, thecatalogue can include all orthodontic devices that the user can purchaseand/or manufacture via the manufacturing device 718. The user interactswith the catalogue via a user input device 714. The user can interactwith the catalogue by navigating the catalogue, making selections fromthe catalogue, modifying orthodontic appliances included in thecatalogue, etc. Accordingly, the user input device 714 can be of anysuitable type, such as a mouse, keyboard, trackpad, touchscreen, etc.The user device 710 also includes a communications radio 716. Thecommunications radio 716 transmits and receives information for the userdevice 710. For example, in the case of a smartphone, the communicationsradio 716 can be a cellular radio operating in accordance with the 4GLTE standard. Once a user has made a selection of an orthodontic device,the user device 710 (e.g., an orthodontic appliance, multipleorthodontic appliances, and orthodontic kit, etc.), via thecommunications radio 716 and the network 708, transmits an indication ofthe selection to the control circuit 702.

The control circuit 702 can comprise a fixed-purpose hard-wired hardwareplatform (including but not limited to an application-specificintegrated circuit (ASIC) (which is an integrated circuit that iscustomized by design for a particular use, rather than intended forgeneral-purpose use), a field-programmable gate array (FPGA), and thelike) or can comprise a partially or wholly-programmable hardwareplatform (including but not limited to microcontrollers,microprocessors, and the like). These architectural options for suchstructures are well known and understood in the art and require nofurther description here. The control circuit 702 is configured (forexample, by using corresponding programming as will be well understoodby those skilled in the art) to carry out one or more of the steps,actions, and/or functions described herein.

By one optional approach the control circuit 702 operably couples to amemory. The memory may be integral to the control circuit 702 or can bephysically discrete (in whole or in part) from the control circuit 702as desired. This memory can also be local with respect to the controlcircuit 702 (where, for example, both share a common circuit board,chassis, power supply, and/or housing) or can be partially or whollyremote with respect to the control circuit 702 (where, for example, thememory is physically located in another facility, metropolitan area, oreven country as compared to the control circuit 702).

This memory can serve, for example, to non-transitorily store thecomputer instructions that, when executed by the control circuit 702,cause the control circuit 702 to behave as described herein. As usedherein, this reference to “non-transitorily” will be understood to referto a non-ephemeral state for the stored contents (and hence excludeswhen the stored contents merely constitute signals or waves) rather thanvolatility of the storage media itself and hence includes bothnon-volatile memory (such as read-only memory (ROM) as well as volatilememory (such as an erasable programmable read-only memory (EPROM).

The control circuit may be remote from the user device 710 and/or themanufacturing device 718. For example, the user device 710 and themanufacturing device 718 may be located in a clinician's office (e.g.,the user's office) whereas the control circuit 702, and possibly thedatabase 704, are cloud-based. The control circuit 702 generallyoperates to retrieve data files 706 based on the user's selection oforthodontic appliances. The control circuit 702 retrieves the data files706 from the database 704. The database 704 is configured to store thedata files 706. The data files 706 are associated with orthodonticdevices. The data files 706 are, for example, CAD files from which theorthodontic devices can be manufactured. The orthodontic device caninclude a carrier and/or orthodontic appliances (i.e., an orthodontickit). Accordingly, the data files include data to additively manufacturethe orthodontic devices. The control circuit 702 receives the indicationof the orthodontic device and retrieves a data file based on theindication of the orthodontic device.

It should be noted that the indication of the orthodontic device mayinclude more than one orthodontic device. For example, the indication ofthe orthodontic device can include multiple orthodontic appliances, suchas full set of brackets for a patient, a set of orthodontic appliancesthat can be used with multiple patients, a carrier, an orthodontic kit,etc. Accordingly, the data file can be a file including instructionsand/or specifications for multiple orthodontic devices. For example, thedata file may include multiple data files and/or multiple specificationsfor a number of brackets.

After retrieving the data file, the control circuit 702 transmits thedata file. In some embodiments, the control circuit 702 encrypts orotherwise protects the data file before transmission. The controlcircuit 702 can encrypt or otherwise protect the data file beforetransmission to prevent those other than the user from accessing thedata file. Additionally, in some embodiments, the control circuit 702can encrypt or otherwise protect the data file to control the user'saccess to the data file. For example, in some embodiments, the system isset up such that user's pay on a per manufacture or per print basis.That is, the user does not purchase, and may not later have access to,the data file. Rather, the user purchases access to print or otherwisemanufacture an orthodontic appliance based on the data file once (orother specified number of times).

Dependent upon the embodiment, the control circuit 702 transmits thedata file to the user device 710, the manufacturing device 718, and/or athird-party device (e.g., a laboratory capable of manufacturing theorthodontic appliance for the user). To whom, or to what device, thedata file is transmitted may also aid in achieving access control. Forexample, in one embodiment, the control circuit 702 transmits the datafile directly to the manufacturing device 718. Because the data file isnot transmitted to the user device 710, the data file may not be easilyaccessible by the user device 710. Further, if an entity that controlsthe control circuit 702 controls the manufacturing device 718, accessmay to files received by the manufacturing device 718 may be furtherlimited. In some embodiments, the control circuit 702 transmits the datafiles to the user device 710. In such embodiments, the user device 710transmits, via the communications radio (e.g., over a universal serialbus (USB) connection, wireless connection based on the 802.11 standard,etc.), the data files to the manufacturing device 718.

The manufacturing device 718 additively manufacturers the orthodonticdevice(s) based on the data file. The manufacturing device 718 can be ofany suitable type, such as a 3D printer. The manufacturing device 718can be local to, or remote from, one or more of the control circuit 702and the user device 710. For example, in one embodiment, the user device710 and the manufacturing device 718 are located in the user's office(i.e., the user device 710 and the manufacturing device 718 are local toone another). Alternatively, the manufacturing device 718 may be locatedin a laboratory or some other facility that manufactures orthodonticdevices for the user.

While the discussion of FIG. 7 provides additional detail regarding asystem for additively manufacturing orthodontic kits, the discussion ofFIG. 8 provides additional detail regarding a process for additivelymanufacturing orthodontic kits.

FIG. 8 is a flow chart including example operations for additivelymanufacturing orthodontic kits, according to some embodiments. The flowbegins at block 802.

At block 802, data files are stored. For example, a database can storethe data files. The database can be of any suitable type and store thedata files in any suitable manner. For example, the database can be arelational database, a NoSQL database, etc. The data files include thedata necessary to additively manufacture orthodontic kits. The flowcontinues at block 804.

At block 804, a data file is received. For example, the data file can bereceived from the database by a user device, control circuit, and/orthird-party device. The flow continues at block 806.

At block 806, the orthodontic kit is additively manufactured. Forexample, a manufacturing device can additively manufacture theorthodontic kit. The manufacturing device manufactures the orthodontickit based on the data file. In one embodiment, the manufacturing devicemanufactures the orthodontic kit my additively manufacturing a carrier,support structures, and orthodontic appliances as a single unit.

In some embodiments, an orthodontic kit comprises a carrier, wherein thecarrier is configured to house a plurality of orthodontic appliances,the plurality of orthodontic appliances, and a plurality of supportstructures, wherein the plurality of support structures includes groupsof support structures, wherein each group of support structures connectsone of the plurality of orthodontic appliances to the carrier, whereinthe orthodontic kit is defined by a computer data file, wherein thecomputer data file includes data necessary to additively manufacture theorthodontic kit including the carrier, the plurality of orthodonticappliances, and the plurality of support structures.

In some embodiments, a system for manufacturing orthodontic kitscomprises a database, wherein the database is configured to store aplurality of computer data files, wherein each of the computer datafiles includes data necessary to additively manufacture an orthodontickit, wherein each of the orthodontic kits includes a carrier, aplurality of support structures, and a plurality of orthodonticappliances, wherein the plurality of support structures includes groupsof support structures, and wherein each group of support structuresconnects one of the plurality of orthodontic appliances to the carrier,and a manufacturing device, wherein the manufacturing device isconfigured to receive, via a network, one of the plurality of datefiles, and additively manufacture, based on the one of the plurality ofcomputer data files, one of the orthodontic kits, wherein the one of theorthodontic kits is associated with the one of the plurality of computerdata files.

In some embodiments, an apparatus and a corresponding method performedby the apparatus comprises storing, in a database, a plurality ofcomputer data files, wherein each of the computer data files includesdata necessary to additively manufacture an orthodontic kit, whereineach of the orthodontic kits includes a carrier, a plurality of supportstructures, and a plurality of orthodontic appliances, wherein theplurality of support structures includes groups of support structures,and wherein each group of support structures connects one of theorthodontic appliances to the carrier, receiving, via a network by amanufacturing device, one of the plurality of computer data files, andadditively manufacturing, based on the one of the plurality of computerdata files, one of the orthodontic kits, wherein the one of theorthodontic kits is associated with the one of the plurality of computerdata files.

Those skilled in the art will recognize that a wide variety of othermodifications, alterations, and combinations can also be made withrespect to the above described embodiments without departing from thescope of the invention, and that such modifications, alterations, andcombinations are to be viewed as being within the ambit of the inventiveconcept.

What is claimed is:
 1. An orthodontic kit, the orthodontic kitcomprising: a carrier, wherein the carrier is configured to house aplurality of orthodontic appliances; the plurality of orthodonticappliances; and a plurality of support structures, wherein the pluralityof support structures includes groups of support structures, whereineach group of support structures connects one of the plurality oforthodontic appliances to the carrier; wherein the orthodontic kit isdefined by a computer data file, wherein the computer data file includesdata necessary to additively manufacture the orthodontic kit includingthe carrier, the plurality of orthodontic appliances, and the pluralityof support structures.
 2. The orthodontic kit of claim 1, wherein thegroups of supports structures have types, and wherein each type isspecific to at least one type of orthodontic appliance.
 3. Theorthodontic kit of claim 1, wherein the computer data file includes allof the data necessary to additively manufacture the orthodontic kit suchthat a manufacturing device additively manufacturing the orthodontic kitdoes not additively manufacture anything in addition to the orthodontickit.
 4. The orthodontic kit of claim 1, wherein the carrier, theplurality of orthodontic appliances, and the plurality of supportstructures are additively manufactured as a single unit.
 5. Theorthodontic kit of claim 1, wherein an orientation of the carrier isincluded in computer data file, wherein the orientation of the carrieris normal to a build plane.
 6. The orthodontic kit of claim 1, whereinthe carrier includes at least one raised rail, wherein the at least oneraised rail extends above the plurality of orthodontic appliances. 7.The orthodontic kit of claim 1, wherein the plurality of orthodonticappliances are oriented with respect to the carrier such that nointernal supports are necessary for the plurality of orthodonticappliances.
 8. A system for manufacturing orthodontic kits, the systemcomprising: a database, wherein the database is configured to: store aplurality of computer data files, wherein each of the computer datafiles includes data necessary to additively manufacture an orthodontickit, wherein each of the orthodontic kits includes a carrier, aplurality of support structures, and a plurality of orthodonticappliances, wherein the plurality of support structures includes groupsof support structures, and wherein each group of support structuresconnects one of the plurality of orthodontic appliances to the carrier;and a manufacturing device, wherein the manufacturing device isconfigured to: receive, via a network, one of the plurality of computerdata files; and additively manufacture, based on the one of theplurality of computer data files, one of the orthodontic kits, whereinthe one of the orthodontic kits is associated with the one of theplurality of computer data files.
 9. The system of claim 8, wherein thegroups of support structures have types, and wherein each type isspecific to at least one type of orthodontic appliance.
 10. The systemof claim 8, wherein each of the plurality of computer data filesincludes all of the data necessary to additively manufacture one of theorthodontic kits such that the manufacturing device does not additivelymanufacture anything in addition to the one of the orthodontic kits. 11.The system of claim 8, wherein each of the orthodontic kits isadditively manufactured as a single unit.
 12. The system of claim 8,wherein an orientation of the carrier is included in the computer datafile, wherein the orientation of the carrier is normal to a build plane.13. The system of claim 8, wherein each carrier includes at least oneraised rail, and wherein the at least one raised rail extends above theplurality of orthodontic appliances associated with each carrier. 14.The system of claim 8, wherein the plurality of orthodontic appliancesare oriented with respect to the carrier such that no internal supportsare necessary for the plurality of orthodontic appliances.
 15. A methodfor manufacturing orthodontic kits, the method comprising: storing, indatabase, a plurality of computer data files, wherein each of thecomputer data files includes data necessary to additively manufacture toadditively manufacture an orthodontic kit, wherein each of theorthodontic kits includes a carrier, a plurality of support structures,and a plurality of orthodontic appliances, wherein the plurality ofsupport structures includes groups of support structures, and whereineach group of support structures connects one of the plurality oforthodontic appliances to the carrier; receiving, via a network by amanufacturing device, one of the plurality of computer data files; andadditively manufacturing, based on the one of the plurality of computerdata files, one of the orthodontic kits, wherein the one of theorthodontic kits is associated with the one of the plurality of computerdata files.
 16. The method of claim 15, wherein the groups of supportsstructures have types, and wherein each type is specific to at least onetype of orthodontic appliance.
 17. The method of claim 15, wherein eachof the plurality of computer data files includes all of the datanecessary to additively manufacture one of the orthodontic kits suchthat the manufacturing device does not additively manufacture anythingin addition to the one of the orthodontic kits.
 18. The method of claim15, wherein each of the orthodontic kits is additively manufactured as asingle unit.
 19. The method of claim 15, wherein an orientation of thecarrier is included in the computer data file, wherein the orientationof the carrier is normal to a build plane.
 20. The method of claim 15,wherein each carrier includes at least one raised rail, and wherein theat least one raised rail extends above the plurality of orthodonticappliances associated with each carrier.
 21. The method of claim 15,wherein the plurality of orthodontic appliances are oriented withrespect to the carrier such that no internal supports are necessary forthe plurality of orthodontic appliances.